Download Installation Maintenance and Safety

Home Refueling Appliance
for CNG vehicles
Mod. HRA G 1.5 P30 & P36
Installation Maintenance and Safety Manual
This Home Refueling Appliance (HRA) should only be installed and
serviced by authorized and trained personnel.
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Page 1
BRC - FuelMaker - M.T.M. S.r.l. U.
Via Industria, 6 - 12062 - Cherasco - CN - ITALY
International Technical Assistance
Tel. +39.0172.48.68.628 0172.48.68.363 - 0172.48.68.623.- Fax +39.0172.486.630
e-mail: [email protected] - www.brcfuelmaker.it
North America – Canada Technical Assistance
Tel. +1.705.341.19.23
e-mail: [email protected]
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SUMMARY
1.
SAFETY INSTRUCTIONS ...................................................................................................................................... 4
2.
INTRODUCTION ................................................................................................................................................. 5
3.
PHILL MODELS ................................................................................................................................................... 5
4.
TECHNICAL SPECIFICATIONS .............................................................................................................................. 6
5.
INSTALLATION INSTRUCTIONS ........................................................................................................................... 6
5.1
5.2
5.3
5.4
6.
GENERAL INFORMATION ...................................................................................................................................... 6
APPLIANCE LOCATION .......................................................................................................................................... 7
HRA INSTALLATION ............................................................................................................................................. 10
EXTERNAL GAS SENSOR INSTALLATION .............................................................................................................. 14
COMMISSIONING .............................................................................................................................................14
6.1
6.2
7.
INITIAL START-UP ................................................................................................................................................ 14
INSTRUCTIONS FOR FINAL USER ......................................................................................................................... 15
FUNCTIONS OF USER’S CONTROL PANEL ..........................................................................................................15
7.1
DISPLAY ERRORS ................................................................................................................................................. 16
8.
MAINTENANCE INSTRUCTIONS .........................................................................................................................22
9.
HRA REMOVAL .................................................................................................................................................22
10.
SAFETY AND DIAGNOSTIC FUNCTIONS .............................................................................................................23
10.1
10.2
SAFETY FUNCTIONS........................................................................................................................................ 23
DIAGNOSTIC FUNCTIONS ............................................................................................................................... 26
11.
RELIABILITY TECHNICAL DATA ..........................................................................................................................38
12.
DISPOSAL..........................................................................................................................................................39
13.
WARRANTY CERTIFICATE ..................................................................................................................................40
14.
CE CONFORMITY DECLARATION .......................................................................................................................41
15.
CERTIFICATE SIL 1 .............................................................................................................................................43
TABLES SUMMARY
Tabella 1 - Phill models ....................................................................................................................................................... 5
Tabella 2 - Technical Specification ...................................................................................................................................... 6
Tabella 3 - Stopping Pressure compared with Ambient Temperature ............................................................................ 14
Tabella 4 - Working Hours codes ...................................................................................................................................... 16
Table 5 – Error diagnostics................................................................................................................................................ 17
Tabella 6 – Safety functions .............................................................................................................................................. 23
Table 7 – Appliance response ........................................................................................................................................... 24
Table 8 – Appliance response time ................................................................................................................................... 25
Table 9 - Appliance response ............................................................................................................................................ 26
Table 10 – System response time ..................................................................................................................................... 34
Table 11 – Failure Probability ........................................................................................................................................... 38
Tabella 12 - Diagnostic Coverage ...................................................................................................................................... 38
Table 13 - Safe Failure Fraction ........................................................................................................................................ 38
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1. SAFETY INSTRUCTIONS
•
COMPONENTS ARE NON REPLACEABLE BY USER
USERs SHOULD NOT CARRY OUT ANY MAINTENANCE ON INTERNAL COMPONENTS.
Internal components should only be maintained and overhauled at BRC FuelMaker’s premises or by authorized
dealers.
Do not open or tamper with modules or the warranty will be invalidated; tampering with or opening modules could be
dangerous and cause damage to the compressor and cause serious injury or even death.
•
READ CAREFULLY BEFORE INSTALLATION
HRAs should only be installed by trained and personnel authorized by BRC FuelMaker.
Please read carefully the manual provided before installation and use. If you have any questions or concerns during
installation, please contact BRC FuelMaker Technical Support.
•
LOCATION OF HOME REFUELLING APPLIANCE (HRA)
HRAs can be installed both indoors (Garage) and outdoors in safe and protected areas as per installation instructions
and local jurisdictional codes.
The HRA and vehicle have to be located in the same ambient temperature during the refuelling operation to ensure
correct temperature compensation.
See Table 2 for temperature compensated maximum fuelling pressures.
•
REFUELING APPLIANCE FOR CNG (Compressed Natural Gas) VEHICLES ONLY
Do not use HRA for any other purpose or it may results in serious injury and/or death to and also cause serious
damage to structures. Vehicle gas cylinder should be certified for storing CNG at a 3600 psig or 250 Bar pressure or
higher. HRA is suitable for residential applications, and all installations must comply with installation manuals and
local jurisdictional code requirements.
•
REFUELING INSTRUCTIONS
Do not refuel with engine turned on and be sure that any possible ignition source is absent. Do not smoke or expose
to open flames during refuelling.
•
IF YOU SMELL GAS
Open all windows and doors in the location of the HRA if the unit is installed indoors.
Immediately close the manual valve on natural gas supply line; and, if possible, the valve on the vehicle cylinder.
Switch off any possible ignition sources and contact an Authorized Service Centre.
•
REFUELING HOSE
The refuelling hose must be protected from damage and abrasion. After refuelling your car, ensure that the refuelling
nozzle is returned to its’ holder. In case of hose and connector abrasions or wear, contact your Authorized Technical
Centre for service.
WARNING : DO NOT USE SOLVENT OR AGGRESSIVE CHEMICAL AGENTS FOR CLEANING THE OUTSIDE. USE
DETERGENTS OR DOMESTIC GENTLE SOAP.
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2. INTRODUCTION
HRA has been developed for both indoors (Garage) and outdoors installation, for compressing Natural Gas for vehicle
use.
Model P30 is designed to refuel at a pressure of 207 bar/3,000 psi at 20° C/68° F (ambient temperature) with a
3
Nominal Flow of 1,3 sm /h at 50 Hz (1.01 scfm-0.5 GGE/h at 60 Hz).
Model P36 is designed to refuel at a pressure of 248 bar/3,600 psi at 15° C/59° F (ambient temperature) with a
3
Nominal Flow of 1,3 sm /h at 50 Hz (1.01 scfm-0.5 GGE/h at 60 Hz).
A HRA is equipped with Internal Gas Sensor/Air Flow Switch and Internal Dryer.
3. PHILL MODELS
Tabella 1 - Phill models
WARNING Phill models without the gas dryer (Smart and Basic) are available but they can be used only if
the gas is already dried. We recommend to use gas with dew point at the maximum delivery pressure of 5°C lower
than the minimum ambient temperature.
WARNING In case of outdoor installation with adequate ventilation the Phill Smart use without the
internal gas detector is allowed
The Phill software is designed for the constant monitoring of the all compressor components. The software checks for
the pressure increasing as well as the maximum filling pressure compensation in reference to the ambient
temperature in order to avoid overpressures due to external temperature rising after filling. The automatic
compensation system is determined by the temperature
temperature sensor installed on the main board (function activated by the
manufacturer).
The Phill is air cooled and admits operating temperature between -40°C/-40°F and +45°C/113°F.
The Phill ventilation system operates through a fan located in the compressor lower
lower side. The cooling air inlet is
equipped with a grid while the exhaust is located in the compressor upper side or rear side.
Start, stop, and monitoring are performed by the User Control Panel.
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4. TECHNICAL SPECIFICATIONS
GAS CIRCUIT
Max Filling Pressure
207 bar (3000 psig) at 20° C (68°F) ambient
248 bar (3600 psig) at 15° C (59°F)ambient
Min Inlet Pressure
17 mbar (7” w.c.)
Max Inlet Pressure
35 mbar (14” w.c.)
Nominal Flow
1.3 sm3/h a 20°C - 0.017 bar inlet
1.01 scfm/0.5 GGE/h @ 68°F 7”w.c.
WIRING CIRCUIT
Electrical Supply
220-240 Volt AC Single Phase, 50/60 Hz
Wiring Circuit Capacity
15 Amp
Full Load Amperes
5.5/5.0 Amp
Average Consumption
0.85 kWh
MECHANICS
Dimensions (L x P x A)
762 x 356 x 330 mm/30”x14”x13”
Weight
49 Kg/110 lb (packaging included)
Noise
40 dBa at 5 mt (16.5 ft)
Covering Protection Level
IP 24
Operating Temperature
from - 40° C to + 46° C (-40°F +115°F)
Tabella 2 - Technical Specification
5. INSTALLATION INSTRUCTIONS
5.1
GENERAL INFORMATION
Open packaging and verify the condition of the appliance; in case of damage due to transportation immediately
contact your local dealer.
Ensure that the gas supply and the electrical
electrical supply provided correspond to the values indicated on the serial number
plate. The Natural Gas connection should be properly done using suitable piping, following installation and testing
procedures in accordance with all codes in place by the authorities have jurisdiction. A shut-off valve must be installed
on the gas supply line, and with a pressure regulator, if the supply pressure exceeds the max value allowed.
Electrical installation should be properly done in accordance with codes determined by the authorities having
jurisdiction. Natural Gas must be odorised. The installation of a HRA must comply with all codes determined by the
authorities having jurisdiction and those outlined in this manual, in each case the more stringent rule must be
followed.
The installation of a HRA must comply with all codes determined by the authorities having jurisdiction and
those outlined in this manual, in each case the more stringent rule must be followed.
- Noise
Phill (HRA) soundproof version emits roughly 40 dBA (Hemispheric Field) at a distance of 5 m (16.5 ft). The installer
should ensure that no noise regulations are in place by the authorities having jurisdiction. Avoid installing a HRA next
to neighbours’ windows or walls that can amplify noise.
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5.2
APPLIANCE LOCATION
- Structure requirements
HRA weighs roughly 43 Kg (95 lb) and should be installed on a wall or a structure made of non-combustible material
able to support min 90 kg (198 lb). The support frame has been designed to reduce noise and vibration transmission
to the wall.
- Vehicle Refueling Point
A HRA must be installed next to the vehicle being refuelled
due to an automatic temperature compensation system
between outlet and ambient temperature pressures;
always consider the max length of refuelling pipe and do
not obstruct pedestrian crossing or passages. Choose a
location to install a HRA on the basis of the vehicle
refuelling point and HRA location, in order to ensure
proper operation of the hose breakaway device in the
event of a driveaway while the hose is connected (see pict.
2-3-4).
- Service Clearances
Be sure that Services Clearances are observed (see pict. 1).
If Service Clearances cannot be observed, please contact
Technical Support. Avoid areas that may allow possible gas
accumulation such as overhangs and/or eaves. Avoid areas
next to vegetation that could obstruct air grilles or subject
to the possible damage due to falling material.
Picture 1 – Service Clearances.
Picture 2 - Example of installation
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Picture 3 - Example of installation
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Picture 4 - Installation Distances
A breakaway device allows the hose to separate if vehicle drives away while the refuelling hose is still connected. It
parts in two to avoid pulling the HRA from its support. In the event of a drive away while the fuelling hose is
connected to the vehicle, the fuelling hose connected to the vehicle can only be removed by means of a
depressurizing tool.
- Impact Protection
HRA should be installed 1,5 mt (5 ft) high from the floor or in a location that will ensure that there is no risk of impact
from a vehicle or other objects in the vicinity. In some cases such as use of a bigger vehicle, such as VAN or SUV, the
HRA may require impact protection such as a bollard (see pict. 5). Always make reference local codes determined by
the authorities having jurisdiction.
Picture 5 – Impact Protection
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COOLING
AIR OUTLET
FIXING
BRACKET
EXT. GAS SENSOR
(optional)
NOZZLE HOLDER
NOZZLE
BREAKAWAY
EXT. GAS SENSOR
AND SERIAL PORT
CONNECTION
REFUELLING
HOSE
COOLING AIR INLET
INLET AND VENT
FITTINGS
Picture 6 - Frontal View
COOLING AIR INLET
VENT FITTING 3/8”
GAS INLET
FITTING 1/2”
SERIAL
PORT
REFUELLING
HOSE
EXT. GAS
CONNECTOR
(optional)
Picture 7 – Hard Mount Brackets
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POWER
SUPPLY
CABLE
Picture 8 - Lower View
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Picture 9 - Support Kit with Soft Mount Vibration and Noise Suppression
5.3
HRA INSTALLATION
- Wall installation
Determine the best mounting method for the HRA from the preceding information. If it’s equipped with hard mount
brackets (see pict. 7), use brackets holes as a template. If it’s equipped with Soft Mount Vibration and Noise
Suppression (see pict. 9), the kit will include:
No. 2 Support Brackets
No. 4 90° Fixing Brackets with Threaded Bush
No. 4 Linear Fixing Brackets with Threaded Bush
No. 1 Bracket Fixing Device
The HRA can be built-in installed between wall studs using the 90° Fixing Brackets or on a flat surface using the Linear
Fixing Brackets. Use the template found in the Accessories Box to mark the brackets mounting holes and the Cooling
Rear Outlet vent path if necessary. Attach the mounting bracket to the wall, do not tighten screws completely and
hang compressor in place on the mounting brackets being careful with to ensure rear hooks ensuring the bracket is
correctly mounted. Once mounted correctly and perpendicular, tighten bracket screws and close the mounting lock
plate.
WARNING: Wall mounts must support the HRA weight and be able to support the unit in the event of a
vehicle driveaway while connected to the Phill ensuring that the breakaway on the hose will disconnect safely.
Affix nozzle holder to the wall, next to the HRA (see pict. 11).
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Picture 10 - Fixing Screws
Picture 11 – Nozzle Holder Mounting
Once correctly mounted, open the front cover of the HRA by removing the 5 cover screws. Loosen the three
transportation mounts (see pict. 10), but do not remove or attempt to remove these mounts. The screws are mounted
to rubber grommets to hold the internal components in place during shipment.
WARNING: HRA can be seriously damaged if you do not loosen the 3 transportation screws. In case having
to ship the HRA, tighten the 3 transportation screws again before shipping, in order to avoid any damage.
- Gas pipe - Inlet
3
HRA should be installed where natural gas network assures a max humidity ratio of 110 mg/m (0.24 lb) (-20° C/-4°F
DewPoint). Inlet pressure should not be lower than 17 mBar (7” w.c.) or higher than the one indicated by technical
information plate in order to avoid damages to the appliance. Install a pressure regulator on the inlet line if necessary.
Gas installation should be properly done by trained and certified personnel. A manual shut-off valve should be
installed in an easy-to-access position on gas pipe. In addition a dirt trap and test port need to be installed before the
inlet to the HRA unit.
Gas inlet pipe is connected to the HRA through the GAS ½” threaded fitting supplied (see pict. 8). In case where
inflexible NG supply pipe is fixed to the wall, we suggest using a flex pipe from the pipe to the connection on the HRA
to prevent the transmission of vibration and noise to the building.
Pipes and connectors should be free from rust, oil, shavings and metallic chards. Liquid or rubber sealant products
should not obstruct pipe.
In case of supply low pressure (17 mBar - 7” w.c.) pipe should have minimum diameter 1”, if pipe is shorter than 3
mt/10 ft. you can use a ø ¾” pipe.
HRA could switch off if other home appliances are working at the same time (e.g. Stove, Heating) on the same supply
line. Regulators installed by gas suppliers and for use at the HRA should be equipped with a device to adjust the supply
line flow and be tested when all natural gas appliances are running.
Check the regulator adjustment by running the HRA compressor and all other home appliances working on the
same NG supply line, adjust to ensure that the minimum inlet pressure to the HRA is maintained.
Materials, installation and testing procedures should comply with applicable laws in force (e.g. UNI-CIG 7129)
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- Gas pipe - Outlet
The HRA refuelling hose should not be replaced by unauthorized personnel not trained by BRC-FuelMaker. Only
approved BRC FuelMaker HRA refuelling hoses can be used as use of unauthorized hoses may cause injury, property
damage and/or death.
- Pressure Relief connection
HRA is equipped with a Pressure Relief with an outlet Gas threaded fitting Gas 3/8” (see pict. 9). The Pressure Relief
has a cap with a screen insert to prevent intrusion of foreign bodies or ice accumulation. The Pressure Relief
discharges gas coming out from Safety Valve set at a max pressure of 3 barg (43.5 psi) situated inside the HRA control
module. In the event that natural gas is released, the check valve on the vehicle fuelling receptacle will require
service.
If HRA needs to be installed in passages, next to windows or next to doors, you will need to connect a pipe to the
pressure relief having inside min ø 10 mm. (3/8”) and this pipe run to an area for the safe release of NG, at least 3 mt
above the floor or grade. Safety distance from discharge point should be at least of 2,5 mt (8.2 ft) sideways from any
possible opening (windows, air inlets or priming sources) and 1 mt (3.3 ft) from below. It is very important that the
pressure relief is free from debris and that water cannot enter into the pipe and freeze. Apply cap with the screen at
the end of the pressure relief line, or provide similar protection (Stainless Steel net).
Please make reference to codes in force by the authorities having jurisdication about the pressure relief pipe position
and pipe dimension.
- Electrical Supply Connection
Electrical installation should be properly done in accordance with the codes in force by the authorities having
jurisdiction. The HRA requires a 220-240VAC electric supply line that should be protected from overcurrent installed in
a visible and easy-to-access position. Check with the authorities having jurisdiction for minimum requirements and
location of a shut off switch.
- Cooling Air Ventilation System Connection
The HRA is equipped with a Cooling AirVentilation system with a fan located internally in the unit. The air enters from
the lower grille (see pict. 8) and exits from either an upper vent (see pict. 7) or a rear vent (see pict. 9), used according
to needs. The HRA is normally provided with the rear hole closed and the upper one open.
An Soundproof Ventilation Kit can also be purchased (see pict. 12 ).
Upper
Casing
Coupler
Modified
Coupler
Lower
Casing
Gasket
Outlet pipe
Picture 12 - Soundproof Ventilation Kit
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Picture 13 - Casings
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In case of an outdoors installation, install the lower casing (if supplied) and the upper top casing (see pict. 13),
following installation instructions.
In case of an indoors installation when using the upper exhaust vent, open the frontal covering, insert modified
coupler supplied in its suitable housing, fix it with the two screws and close covering again. Install a ø 127 mm (5”)
pipe using gasket supplied (see pict. 14) then route the vent piping outside.
It is mandatory to install Lower Casing on HRA.
Picture 14 - Coupler
Picture 15 - External Hood
If using the exhaust vent rear hole, the template provide in the accessory kit will allow you to mark out an exit hole
(hole ø 170 mm/6.7”) while installing mounting brackets. Remove the rear exhaust cap and secure it onto the upper
hole housing. Place coupler on rear hole using the two screws supplied. We suggest to use an external grille as shown
in picture in order to avoid air entering into the discharge duct causing defaults or block of HRA (see pictures 15 and
16).
Picture 16 - Ventilation with Rear hole
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5.4
EXTERNAL GAS SENSOR INSTALLATION
HRA can be equipped with External Gas Sensor (Optional) if necessary. The connector on the cable from the external
gas sensor needs to be connected to port situated in the lower side of HRA, next to the serial one (see pict. 8). Once
the sensor installed, you need to enable through the software. Connect diagnostic tool HTTP4 (Optional) to the serial
.
port, following instructions under programming, turn the External Interlock to ON.
IMPORTANT: Disconnect electrical supply for at least 1 minute after resetting the programming. Failure to
turn the unit off for 1 minute and restarting the HRA will not reset the programming.
6. COMMISSIONING
WARNING: HRA should only be commissioned by qualified personnel. Local laws in force could require site
and/or installation inspection before starting up. Contact authorities having jurisdication and gas supplier company
for further requirements and information.
6.1
INITIAL START-UP
- Purge inlet pipes and equipment of air before the initial start-up.
•
•
•
•
•
•
•
•
Switch HRA on.
Open manual valve of gas inlet line.
Wait for the end of software control cycle (Blinking Green LED becomes fixed).
Connect Refuelling hose nozzle to an open refuelling receptacle.
Push the START button and let the pipe discharge for 30seconds.
Check that cooling fan is working good verifying air flow coming out from the front grille if equipped with
upper casing, or opening the front covering.
After discharging, stop compressor, disconnect pipe and start HRA again waiting for its automatic stopping.
Check possible leakages from equipment and connection using a leak detector.
Pressure P30
Pressure P36
207 ± 7bar (3,000± 100 psi)
248 ± 7.0 bar (3,600 ± 100 psi)
183 ± 7.5 bar (2,654 ± 108 psi)
229 ± 7.5 bar (3,321 ± 108 psi)
166 ± 8.0 bar (2,407 ± 116 psi)
211 ± 8.0 bar (3.060 ± 116 psi)
150 ± 8.5 bar (2,175 ± 123 psi)
194 ± 8.5 bar (2,813 ± 123 psi)
133 ± 9.0 bar (1,929 ± 130.5 psi)
177 ± 9.0 bar (2.567 ± 130.5 psi)
116 ± 9.5 bar (1,682 ± 137.7 psi)
160 ± 9.5 bar (2,320 ± 137.7 psi)
100 ± 10.0 bar (1,450 ± 145 psi)
143 ± 10.0 bar (2,074 ± 145 psi)
Tabella 3 - Stopping Pressure compared with Ambient Temperature
Ambient Temperature
21° / 15° C (70° / 59° F ) or higher
10° C – 50° F
0° C – 32° F
- 10° C – 14° F
- 20° C - -4° F
- 30° C - -22°F
- 40° C - -40° F
If ambient temperature detected is lower than - 40° C (-40° F) or higher than +45° C (113° F) the software will not
allow the HRA start-up for safety reasons and an error condition will be indicated on the User’s Control Panel.
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6.2
INSTRUCTIONS FOR FINAL USER
Before leaving, installer should verify the complete installation and advise the customer not to service HRA internal
components. He should give user the HRA User Manual together with suitable instructions about operation, error
codes and what to do in the case of an error code. Routine maintenance instructions should be given to the customer
including hose inspection and nozzle cleaning. Have the HRA User fill in the form outlining understanding of the unit.
The End User should periodically verify that air inlets and discharge system are free from dirt or obstructed, that
refueling hose does not show abrasions or signs of breakage and that vehicle fuelling system is tested and compliant
to safety regulations.
7. FUNCTIONS OF USER’S CONTROL PANEL
Through the User’s Panel, you can Start, Stop and Control unit Error or State Codes. Panel has a START button (Green),
a STOP button (Red), three LEDs (Green) on the left showing State of the unit, Presence of Electrical Supply, Refuelling,
Active Dryer Regeneration and Error (Red), and 5 LEDs on the right showing Fuel level indication, Errors or Working
Hours (see pict. 17).
START
(STARTING REFUELING)
PRESENCE OF
ELECTRICAL SUPPLY
FUEL LEVEL
INDICATORS
REFUELING
ACTIVE DRYER
REGENERATION
ANOMALY
STOP
(ERROR)
(STOP REFUELING)
Picture 17 - User’s Control Panel
HRA is equipped with a diagnostic software constantly controlling the unit working. Light indicators can show different
conditions by pushing START and STOP buttons in a specific sequence.
6.1
DISPLAY HRA WORKING HOURS
Push STOP to reset panel, then keep START and STOP buttons pressed. Fuel level indicators lights will show unit working
hours. See table below to identify hours code (see table 3).
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Tabella 4 - Working Hours codes
7.1
DISPLAY ERRORS
In case of an error condition, the system stops the HRA operation. Depending on the error condition, the unit may be
reset or service may be required. If the system considers the error condition not dangerous, refuelling will restart by
first pushing the STOP button to reset Panel and then the START one. In case of an error code showing a possibly
dangerous situation, this operation will lock out and a service technician will be required to examine the unit.
WARNING: If software blocks HRA from operation, do not disconnect electrical supply as the unit will ensure
that natural gas does not accumulate to prevent damage, injury and/or death.
By keeping the STOP button pressed, User’s panel will display the last error code recorded. A PC diagnostic software is
available to display unit current parameters and Errors Archive. See table below to identify error code and know the
possible corrective action to carry out.
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ERROR CODE
CORRECTIVE ACTION
- Check the right inlet
pressure
- Check that inlet manual
valve is open
- Check the adequate
diameter of supply pipe
- Check reducer (if present).
Low Inlet Pressure
ERROR CODE
CORRECTIVE ACTION
- Check that voltage range is
included between 216 V AC
and 252 V AC
- Check right connection to
the electrical supply line.
Engine Overvoltage
00101
00001
- Disconnect electrical
supply for 1 minute and
connect it again.
- Check possible external
cause:
- Refueling fitting
- Vehicle equipment
- Refueling pipe
- Gas Inlet pipe
- Material stored into
refueling area
- If anomaly persists, call
technical support.
High pressure sensor
malfunction
Int. Gas Sensor Alarm
00110
00010
- Ambient temperature out of
max allowed threshold:
_ Tamb < -45°C
_ Tamb > 55°C
- Disconnect electrical
supply for 1 minute and
connect it again.
- If anomaly persists, call
technical support.
- Temperature sensor
malfunction:
Call technical support.
Excessive high pressure
detected
Ambient temperature out of
range
10111
01110
Possible high pressure gas
inlet from tank.
Try to stop and restart the
appliance every 5-10
minutes.
If problem persists, close
vehicle manual valve, call
technical support.
Do not use vehicle until
anomaly has been
detected.
Excessive
blow down pressure
If no causes are found, close
gas manually and call
technical support.
Check possible leakages:
- Safety Disconnection device
- Refueling fitting
- Vehicle filling point
Inadequate Pressure Increase
00111
This same error can occur if
vehicle tank is almost empty.
Partially refill tank. Try to
restart the appliance many
times.
00011
Table 5 – Error diagnostics
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ERROR CODE
CORRECTIVE ACTION
Check:
- Supply voltage.
- Possible air inlets
obstruction
- Air discharge dimension,
min 125 mm max length 15
mt with max 3 changes of
direction.
ERROR CODE
CORRECTIVE ACTION
Check possible leakages:
- Safety Disconnection device
- Refueling fitting
- Vehicle equipment and filling
point.
Engine Overtemperture
High Pressure Drop
00100
01000
- Disconnect electrical
supply for 1 minute and
connect it again.
- Disconnect electrical supply
for 1 minute and connect it
again.
- If anomaly persists, call
technical support.
- If anomaly persists, call
technical support.
Bypass-valve Malfunction
Combi-valve Malfunction
11000
10110
Dryer Condenser or
vaporizer or heater
malfunctioning.
Dryer condenser temperature
out fo range
<-55 °C or > 105°C
Call technical support.
Call technical support.
Dryer condenser temperature
out of range
Dryer Malfunction
10000
11001
Dryer vaporizer
temperature out of range
<-55 °C or > 105°C
- Disconnect electrical supply
for 1 minute and connect it
again.
Call technical support.
- If anomaly persists, call
technical support.
Excessive Peltier absorption
Dryer vaporizer temperature
out of range
11011
11010
Table 5 – Error diagnostic (Continued)
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Page 18
ERROR CODE
CORRECTIVE ACTION
Check:
- Possible cooling air inlets
obstruction
- Air discharge dimension,
min 125 mm max length 15
mt with max 3 changes of
direction
- Fan
Inadequate Cooling Air Flow
ERROR CODE
Ext. Gas Sensor Alarm
01001
01101
- Check possible leakages:
- Refueling fitting
- Vehicle equipment
- Refueling pipe
CORRECTIVE ACTION
- Check possible external
cause:
- Refueling fitting
- Vehicle equipment
- Refueling pipe
- Gas Inlet pipe
- Material stored into
refueling area
Eliminate leakage source
(close manual valve) and call
authorized technical support.
Disconnect electrical supply
for 1 minute and connect it
again.
If anomaly persists, call
technical support.
Restart the appliance.
Max Refueling Time
Memory error (EPROM, FLASH,
RAM)
01010
11111
Check conformity of gas
supply line pressure to
technical specifications.
Check the right kind and
setting of reducer (if
present).
High Inlet Pressure
Back-Pressure
01011
22222
Check possible obstructions
or damages:
Check:
- Connections
- Adapter board
- Cables
- Safety Disconnection
device
- Refueling fitting
- Vehicle filling point
- Refueling pipe
High Pressure Gas Leakage
Try to stop and restart the
appliance.
Start Button Error
01100
Table 5 – Error diagnostic (Continued)
39.0151
Do not disconnect electrical
supply. Do not force
refueling fitting
disconnection from vehicle.
Try to stop and restart HRA
every 5-10 minutes.
If problem persists, close
vehicle manual valve, call
technical support.
Do not use vehicle until
anomaly has been detected.
If problem persists, replace
user’s control panel.
10001
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Page 19
ERROR CODE
CORRECTIVE ACTION
Check:
ERROR CODE
- Connections
- Adapter board
- Cables
CORRECTIVE ACTION
- Check possible cooling
system obstruction
- Check the free movement
of flow meter blade
- Check sensor supply voltage
- Replace flow meter
Try to stop and restart the
appliance.
If problem persists, replace
user’s control panel.
Stop Button Error
Flow Meter Error
01111
10010
- Check and clean internal
gas sensor
- Check sensor supply
voltage
- Check connections
- Replace sensor
- Check sensor supply
voltage
- Replace sensor
Wrong Int. Gas Sensor
Calibration
Int. Gas Sensor Error
10011
10100
Disconnect electrical supply
for 1 minute and connect it
again.
- Problem probably due to
excessive line voltage
brownout.
- If anomaly persists, call
technical support.
- If line is ok, disconnect
electrical supply for 1 minute
and connect it again.
POWER OFF Error
TRIAC Error
If problem persists, call
technical support.
11110
10101
- Possible communication
failure of tao remove
device, check connection
-Possible high pressure pipe
obstruction in case of
unexpected pressure increase
- Call technical support.
- If connection is ok, call
technical support
Remote Communication Error
Unexpected pressure increase
11101
11100
Table 5 – Error diagnostic (Continued)
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Page 20
ERROR CODE
Mapping Error
CORRECTIVE ACTION
EEprom mapping has not
been correctely recorded.
- Disconnect electrical
supply for 1 minute and
connect it again.
If problem persists, call
technical support.
ERROR CODE
CORRECTIVE ACTION
- Software should be
reloaded onto the board.
- Call technical support.
System in Boot Loader
Table 5 – Error diagnostic (Continued)
6.2
SPECIAL FUNCTIONS
Optional functions that can be only supplied by the manufacturer:
• “Empty Tank” function
If tank is completely empty, this function allows realizing a forced compression to create condition needed to
overcome High Pressure Gas Leakage.
Compressor lays in stand-by and refueling and anomaly indicators start to blink. Press three times, in three
seconds, START button to enable this function (in case of fault procedure, the High Pressure Gas Leakage error is
shown)
During compression, refueling indicator is on while the anomaly one is blinking.
At the end of compression a leakage test is carried out. If there are no leaks anomaly indicator switch off and
compressor keep compressing (on the contrary, the High Pressure Gas Leakage error is shown and compressor
stops).
“Empty Tank” function can be interrupted through the STOP button at any time; the High Pressure Gas Leakage
error is shown.
During the Empty tank phase (anomaly indicator is blinking) user’s monitoring is suggested.
• “Final Pressure Compensation” function according to temperature.
If temperature changes, final refueling pressure changes according to the installation Country’s laws in force. This
function can be disabled if not required.
• “Regeneration Bypass” function
If a dryer error persists during regerenation, compressor stops this operation and allows restoring system
compression functions.
During regeneration bypass, regeneration indicator is blinking. If regeneration ends successfully, bypass the
indicator will swcith off.
• Diaphragm Vaporizer function (Nafion function)
If diaphragm temperature is lower than 5°C, this function switches diaphragm heater on. It will switch off when
temperature goes beyond the 7°C. It is necessary to avoid possible freezing of water present into the diaphragm.
• CMPDrying
This function can be carried out before regeneration to collect humidity present into the compressor (some
conditions should be satisfied: regeneration time, refueling has started from 4s only, outlet pressure ≤400 psi).
This function is not available for versions without dryer.
• Dryer, GAS leakage detection, Air Flow Control
Versions without one of this element are available, as already said.
Optional functions that can be enabled by the dealer, after manufacturer’s authorization:
• External gas sensor (provided by the manufacturer).
• Max time configuration of a single compression.
• Pressure increase control (Inadequate pressure increase).
• Service option enabling (gradual decrease of final pressure after passing max working hours set up by the
manufacturer).
• Configuration of compressiontime between two regenerations.
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Page 21
8. MAINTENANCE INSTRUCTIONS
The end user or unauthorized personnel should not access internal components for safety reasons; after installation,
authorized personnel should close Cover applying the suitable seal provided with the handbook. HRA should only kept
maintained by authorized personnel suitably trained.
Technical service should always:
1
2
3
4
Compare errors shown by HRA with table 4
Try to solve problem verifying installation or replacing components
Test HRA to verify if problems have been eliminated
Close and seal HRA
WARNING:
Any other operation not described in this manual should only be carried out by BRC-FuelMaker at its premises. Any
service completed by UNAUTHORIZED personnel will invalidate
invalidate the warranty and may cause damage to the
compressor, serious injury and/or death .
- Ordinary Maintenance Inspection
Periodically check the outlet pressure to ensure proper operation (see table 2), verify that refuelling hose does not
show abrasions, cutting or swelling; replace it if necessary. Always check refuelling
refuelling nozzle and breakaway device,
replace them if necessary. Check that pressure relief and front/rear air inlets are free from material or ice.
Any attempt to tamper with or open modules can cause damage to property, serious injury and/or death; and will
invalidate the warranty.
9. HRA REMOVAL
If you need to remove the unit, follow these instructions:
•
•
•
•
Check that Electric Supply button is OFF and gas inlet valve closed.
Check the absence of voltage on electric supply cable and disconnect it.
Disconnect Inlet and Discharge pipe from HRA verifying the absence of overpressures; close fittings.
Pack HRA with its original packaging.
For further information, please feel free to contact Technical Service.
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Page 22
10. SAFETY AND DIAGNOSTIC FUNCTIONS
10.1 SAFETY FUNCTIONS
The following table shows appliance safety functions. They are indicated by the letter SF (Safety Function) followed by
a progressive index.
Number
SF1
Description
Leaks detection on
Gas high pressure
line
Safety functions
Phase involved
Operation mode
Protection – Low demand
Refueling
mode
Control and monitoring –
Continuous mode (dryer)
periodically activated
(Regeneration)
Protection – Low demand
mode
Application
Outdoor /
Indoor
Exception
-
SF2
Humidity elimination
through Dryer
function
SF3
Gas Leakage
detection
SF4
Detection of
inadequate air flow
Protection – Low demand
Refueling,
mode
Regeneration
Indoor
-
SF5
Inlet pressure
detection and
verification of limits
allowed
Protection – Low demand
Refueling,
mode
Regeneration
Outdoor /
Indoor
-
SF6
Outlet pressure
control and
monitoring
Protection – Low demand
First seconds from
mode
Outdoor /
starting,
Control and monitoring –
Indoor
Refueling
Continuous mode
-
Refueling,
Regeneration
Outdoor /
Indoor
Always, except for
the first minute
Indoor
from starting
CNG dew point
-
Tabella 6 – Safety functions
The following table shows system response when a safety function is broken (hazard).
System puts itself in safe condition:
o Engine off.
o Combi Valve off (eventually switched on again in case of Blowback anomaly detected).
o All Dryer actuators off (Peltier-Condenser, ByPass Valve, Column heater, Diaphragm HeaterVaporizer if Nafion function is disabled).
o Buzzer, indicators, fan, engine relay and blow back managed according to the specific safety
function.
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Page 23
Safety function
SF1
SF2
SF3
SF4
SF5
SF6
Appliance response in case of Safety Function Intervention
System response
User’s Interface Response
System puts itself in safe condition
- ANOMALY indicator on
and:
- REFUELING indicator off
-Fan on
- REGENERATION indicator off
- BlowBack algorithm activation
-Buzzer is on for 5 seconds
- Anomaly recorded on memory
Dryer function (gas dehumidifier)
always activated.
- ANOMALY indicator off (if there are
Dryer regeneration uses: Engine,
no anomalies detected)
ByPass Valve (Combi Valve should
- REFUELING indicator off
be off), Fan, Diaphragm Vaporizer,
- REGENERATION indicator on (if there
Column Heater, Condenser (Peltier).
are no anomalies detected)
If anomaly is detected during
-Buzzer off (if there are no anomalies
regeneration, system puts itself in
detected)
safe condition (the specific response
depends on the kind of anomaly).
System puts itself in safe condition
and:
- ANOMALY indicator on
- Fan on
- REFUELING indicator off
- BlowBack algorithm activation (if
- REGENERATION indicator off
system was refuelling)
-Buzzer on
- Anomaly recorded on memory
System puts itself in safe condition
and:
- Fan on (except for flow meter
- ANOMALY indicator on
error and max number of restarting,
- REFUELING indicator off
allowed after an anomaly detected,
- REGENERATION indicator off
not yet achieved)
-Buzzer is on for 5 seconds
- BlowBack algorithm activation (if
system was refuelling)
- Anomaly recorded on memory
System puts itself in safe condition
and:
- ANOMALY indicator on
- Fan on
- REFUELING indicator off
- BlowBack algorithm activation (if
- REGENERATION indicator off
system was refuelling)
- Buzzer is on for 5 seconds
- Anomaly recorded on memory
System puts itself in safe condition
- ANOMALY indicator on *
and:
- REFUELING indicator off
- Fan on
- REGENERATION indicator off
- BlowBack algorithm activation
- Buzzer is on for 5 seconds
- Anomaly recorded on memory
Table 7 – Appliance response
*In case of BlowBack enabled error, buzzer emits an intermittent sound. In case of BlowBack enabled and/or detected
error, refueling indicators (DISPLAY) start to blink.
The following table shows time intervals of safety functions and system response times in case of violation (this
estimates software and actuators response time).
Test interval does not consider: sensors response time, input acquisition time (including average calculation and
software filters implemented, that change from input to input according to the kind), test duration.
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Page 24
System Response Time
Safety function
Test Interval
After 6 seconds from refueling (repeated
after 36 seconds if first test fails, repeated
after the Empty Tank if enabled), every 130
SF1
min of refueling and when outlet pressure is
97% of the final allowed one and the system
is refueling from at least 5 min.
Dryer function is always enabled during
compression when gas passes through.
Regeneration enabled:
-every lapse of time expected between two
SF2
regenerations if outlet pressure is > 400 PSI.
-If filling final pressure has been > 400PSI and
at least 75% of max time between two
regenerations is elapsed and system is in
stand-by from at least 30 min.
About every 10ms (except during the first
SF3
minute of refueling)
About every 10ms (except during the first
SF4
seconds of refueling)*.
About every 10ms (except during the first
SF5
seconds of refueling; pressure higher limit is
verified only after at least 5 min running)*.
About every 10ms (final pressure is verified
during refueling).
About every 10ms: outlet pressure sensor
limit are verified (except during the first
seconds of refueling)*
About every 1s during refueling: Unexpected
increase/drop of outlet pressure.
5s after the end of refueling and during the
SF6
first seconds of supply (about after 6 sec),
BlowBack is enabled (if test KO, system
repeats after 16 sec and then after every 15
min; test can be forced by pressing STOP
button).
When system starts refueling/regeneration
process, software carries out the blow down
test.
Table 8 – Appliance response time
Response Time
~2s
~2s
~2s
~2s
~2s
~2s
*In case of condition violation, the system reacts (putting itself in safe condition) just in case of refuelling or
regeneration.
With Running, we intend refueling or regeneration started from a refueling process.
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Page 25
10.2 DIAGNOSTIC FUNCTIONS
The following table shows diagnostic functions and system response when a Fault/Hazard is detected.
System puts itself in safe condition:
o Engine off.
o Combi Valve off (eventually switched on again in case of Blowback anomaly detected).
o All Dryer actuators off (Peltier-Condenser, ByPass Valve, Column heater, Diaphragm HeaterVaporizer if Nafion function is disabled).
o Buzzer, indicators, fan, engine relay and blow back managed according to the specific Hazard/Fault
detected.
The table also shows Diagnostic Coverage of single functions.
Number
1
2
3
Device/
function
LPT
(Low Pressure
Transducer –
low limit)
Appliance response in case of Diagnostic Functions intervention
User’s interface
Description
System response
response
Hazard
Low inlet pressure
System puts itself in safe
- ANOMALY
condition and:
indicator on
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
LPT
(Low Pressure
Transducer –
high limit)
High inlet pressure
HPT
(High
Pressure
Transducer –
high limit)
Excessive high pressure
detected
System puts itself in safe
condition and:
-Fan on
- BlowBack algorithm
activation (if system was
refuelling)
- Anomaly recorded on
memory
System puts itself in safe
condition and:
-Fan on
- BlowBack algorithm
activation (if system was
refuelling)
- Anomaly recorded on
memory
- ANOMALY
indicator on
- REFUELING
indicator off
-REGENERATION
indicator off
- Buzzer is on for
5 seconds
- ANOMALY
indicator on
- REFUELING
indicator off
-REGENERATION
indicator off
- Buzzer is on for
5 seconds
Diagnostic
Coverage
Low –
60%
Low –
60%
Low –
60%
Table 9 - Appliance response
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Page 26
Appliance response in case of Diagnostic Functions intervention
High pressure sensor
System puts itself in safe
- ANOMALY
malfunction
condition and:
indicator on
-Fan on
- REFUELING
indicator off
- BlowBack algorithm
-REGENERATION
activation (if system was
indicator off
refuelling)
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
5
AIR FLOW
Inadequate cooling air flow System puts itself in safe
- ANOMALY
(inadequate
condition and:
indicator on
air flow)
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Buzzer is on for
- Anomaly recorded on
memory
5 seconds
6
AIR FLOW
Flow meter error
System puts itself in safe
(flow meter
condition and:
- ANOMALY
out of order)
- Fan on (except for max
indicator on
- REFUELING
number of restarting after
anomaly is passed)
indicator off
- BlowBack algorithm
-REGENERATION
indicator off
activation (if system was
- Buzzer is on for
refuelling)
- Anomaly recorded on
5 seconds
memory
7
COMBI
Combi Valve malfunction
System puts itself in safe
- ANOMALY
indicator on
VALVE
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
activation (if system was
-REGENERATION
refuelling)
indicator off
- Buzzer is on for
- Anomaly recorded on
5 seconds
memory
8
INTERNAL
Internal gas sensor alarm
System puts itself in safe
- ANOMALY
GAS ALARM
condition and:
indicator on
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer on
memory
Table 9 – Appliance response (Continued)
4
39.0151
HPT
(High Pressure
Transducer –
low limit)
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Low –
60%
High –
90%
High –
90%
High –
90%
Low –
60%
High –
90%
Page 27
Appliance response in case of Diagnostic Functions intervention
Wrong Internal gas sensor
System puts itself in safe
- ANOMALY
Calibration
condition and:
indicator on
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer on
memory
10
INTERNAL
Internal gas sensor Error
System puts itself in safe
- ANOMALY
GAS ALARM
condition and:
indicator on
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer on
memory
11
EXTERNAL
External gas sensor alarm
System puts itself in safe
- ANOMALY
GAS
condition and:
indicator on
SENSOR
-Fan on
- REFUELING
(OPTIONAL)
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer on
memory
12
DRYER
Dryer malfunction
- ANOMALY
System puts itself in safe
GENERAL
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- Anomaly recorded on
-REGENERATION
memory
indicator off
- Buzzer is on for
5 seconds
- ANOMALY
13
BY PASS
ByPass Valve malfunction
System puts itself in safe
indicator on
VALVE
condition and:
- REFUELING
-Fan on
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
5 seconds
memory
14
DRYER
Dryer condenser
System puts itself in safe
- ANOMALY
CONDENSER
temperature out of range
condition and:
indicator on
TEMPERATURE
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
-REGENERATION
activation (if system was
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Table 9 – Appliance response (Continued)
9
39.0151
INTERNAL
GAS ALARM
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Low –
60%
High –
90%
Low –
60%
High –
90%
Low –
60%
High –
90%
Medium
– 90%
High –
90%
Medium
– 90%
Page 28
Appliance response in case of Diagnostic Functions intervention
Dryer vaporizer temperature System puts itself in safe
out of range
condition and:
- ANOMALY
-Fan on
indicator on
-Vaporizer switching off
- REFUELING
(even if Vaporizer function
indicator off
is enabled)
-REGENERATION
- BlowBack algorithm
indicator off
activation (if system was
- Buzzer is on for
refuelling)
5 seconds
- Anomaly recorded on
memory
16
DRYER
Excessive
- ANOMALY
PELTIER
Peltier absorption
System puts itself in safe
indicator on
CURRENT
(Condenser)
condition and:
- REFUELING
-Fan on
indicator off
- Anomaly recorded on
-REGENERATION
indicator off
memory
- Buzzer is on for
5 seconds
17
MOTOR
Triac error
System puts itself in safe
- ANOMALY
TRIAC
condition and:
indicator on
-Fan on
- REFUELING
-Engine relay opening
indicator off
- BlowBack algorithm
-REGENERATION
activation (if system was
indicator off
refuelling)
- Buzzer is on for
- Anomaly recorded on
5 seconds
memory
18
MOTOR
Engine overtemperature
System puts itself in safe
- ANOMALY
TCO
(TCO)
condition and:
indicator on
- REFUELING
-Fan on
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
19
MOTOR
Engine Overcurrent
System puts itself in safe
- ANOMALY
condition and:
indicator on
- REFUELING
-Fan on
- BlowBack algorithm
indicator off
activation (if system was
-REGENERATION
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Table 9 – Appliance response (Continued)
15
39.0151
DRYER
EVAPORATOR
TEMPERATURE
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Medium
– 90%
High –
90%
High –
90%
High –
90%
High –
90%
Page 29
Appliance response in case of Diagnostic Functions intervention
Outlet high pressure
- ANOMALY
System puts itself in safe
unexpected drop
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
-REGENERATION
activation
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
21
BLOWDOWN
Excessive BlowDown
- ANOMALY
System puts itself in safe
pressure
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- Anomaly recorded on
-REGENERATION
memory
indicator off
- Buzzer is on for
5 seconds
22
BLOWBACK
Back-pressure (BlowBack)
- ANOMALY
System puts itself in safe
indicator on
condition and:
- REFUELING
-Fan on
indicator off
-Combi Valve on (except
-REGENERATION
when system verifies if
indicator off
pressure decreases to not
- Buzzer blinking
dangerous values)
-Refueling
- Anomaly recorded on
indicators
memory
(DISPLAY) blinking
23
SUDDEN
Outlet pressure unexpected
- ANOMALY
System puts itself in safe
PRESSURE
increase
indicator on
condition and:
RISE
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
-REGENERATION
activation
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
24
HOSE TEST
High pressure gas leakage
- ANOMALY
System puts itself in safe
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
-REGENERATION
activation
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Hardware fault
25
AMBIENT
Ambient temperature
System puts itself in safe
- ANOMALY
indicator on
TEMPERATURE
out of range
condition and:
SENSORS
-Fan on
- REFUELING
- BlowBack algorithm
indicator off
-REGENERATION
activation (if system was
indicator off
refuelling)
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Table 9 – Appliance response (Continued)
20
39.0151
SUDDEN
PRESSURE
DROP TEST
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NA
NA
NA
NA
NA
Low –
60%
Page 30
Appliance response in case of Diagnostic Functions intervention
START button error
System puts itself in safe
- ANOMALY
condition and:
indicator on
-Fan on (is system was
- REFUELING
refueling/regenerating)
indicator off
- BlowBack algorithm
-REGENERATION
activation (if system was
indicator off
refuelling)
- Buzzer is on for
- Anomaly recorded on
5 seconds
memory
27
STOP
Stop button failure
- ANOMALY
BUTTON
indicator on
System puts itself in safe
- REFUELING
condition and:
indicator off
-Fan off
-REGENERATION
- Anomaly recorded on
indicator off
memory
- Buzzer is on for
5 seconds
Pressure management faults
28
PRESSURE
Inadequate pressure
- ANOMALY
System puts itself in safe
RISE TEST
increase
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
-REGENERATION
activation
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Counter timer faults
29
MAX
Max allowed number of
System puts itself in safe
- ANOMALY
indicator on
RESTART
error for compressor restart condition and:
- REFUELING
passed
-Fan on
indicator off
- BlowBack enabled from
last error detected (if
-REGENERATION
system was refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
30
MAXFILL
Max filling time
- ANOMALY
System puts itself in safe
TIME
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
-REGENERATION
activation
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
Table 9 – Appliance response (Continued)
26
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BUTTON
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Low –
60%
Low –
60%
NA
NA
NA
Page 31
Appliance response in case of Diagnostic Functions intervention
Max allowed number of
- ANOMALY
reset (e.g. Watch Dog) in
indicator on
System puts itself in safe
refueling/
- REFUELING
condition and:
regeneration passed
indicator off
-Fan on
-REGENERATION
- Anomaly recorded on
indicator off
memory
- Buzzer is on for
5 seconds
Software faults
32
EEPROM
EEPROM Error
System puts itself in safe
- ANOMALY
condition and:
indicator on
-Fan on
- REFUELING
indicator off
- BlowBack algorithm
-REGENERATION
activation (if system was
refuelling)
indicator off
- Anomaly recorded on
- Buzzer is on for
memory
5 seconds
33
FLASH
FLASH Error
System puts itself in safe
- ANOMALY
condition and:
indicator on
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
activation (if system was
-REGENERATION
indicator off
refuelling)
- Buzzer is on for
- Anomaly recorded on
5 seconds
memory
34
RAM
RAM Error
System puts itself in safe
- ANOMALY
indicator on
condition and:
- REFUELING
-Fan on
indicator off
- BlowBack algorithm
activation (if system was
-REGENERATION
indicator off
refuelling)
- Buzzer is on for
- Anomaly recorded on
5 seconds
memory
35
MAP
Mapping/Calibration error
- Supply indicator
EEPROM KO
blinking
- ANOMALY
System puts itself in safe
indicator on
condition and:
- REFUELING
-Fan on
indicator off
-REGENERATION
indicator off
- Buzzer is on for
5 seconds
Table 9 – Appliance response (Continued)
31
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NA
Low –
60%
Low –
60%
Medium
– 90%
Low –
60%
Page 32
Appliance response in case of Diagnostic Functions intervention
Mapping/Calibration error
- Supply
indicator
blinking
System puts itself in safe
- ANOMALY
condition and:
indicator on
-Fan on
- REFUELING
indicator off
-REGENERATION
indicator off
- Buzzer is on for
5 seconds
36
REMOTE
Remote communication
System puts itself in safe
- ANOMALY
COMMUNIC.
error
condition and:
indicator on
STATUS
-Fan on
- REFUELING
indicator off
- BlowBack algorithm
-REGENERATION
activation (if system was
indicator off
refuelling)
- Buzzer is on for
- Anomaly recorded on
memory
5 seconds
37
RS-232
RS-232 CRC error
No system response
- Diagnostic
because the problem only
interface
disconnected or
concerns communication
with diagnostic interface
problems in
displaying
parameters
38
WATCH
Watch Dog function
System switches off and
- Supply indicator
DOG
then restarts
blinking for
system restarting
Table 9 – Appliance response (Continued)
35
MAP
EEPROM KO
Low –
60%
Low –
60%
High –
90%
Low –
60%
Notes:
• DC shown in table is the Diagnostic Coverage concerning failures for diagnosed block as a whole, while DC
shown in FMEDA should be the specific value of single failure mode;
• In table, DC = 90% has been conservatively used even in case of DC High
The following table shows time intervals of diagnostic functions and system response times in case of violation (this
estimates software and actuators response time).
Test interval does not consider: sensors response time, input acquisition time (including average calculation and
software filters implemented, that change from input to input according to the kind), test duration.
The system can carry out manual/automatic restarting in the same refueling/regeneration cycle after a fault/hazard
detection. The first starting can only be manual.
The following table shows (in error type column) the kind of restarting determined by corresponding fault/hazard:
- Type A: automatic restarting after 15s;
- Type B: automatic restarting when anomaly has been solved (and at least after 15s from its detection);
- Type C: automatic restarting after 10minutes, you can advance restarting manually;
- Type D: manual restarting;
- Type E: manual restarting if anomaly has been solved;
- Type F: automatic restarting is possible but a switching off (< 1 minute) is necessary. If system is not reset, appliance
cannot restart (if you press stop and then start the system starts a new cycle but error is promptly detected because
the anomaly can only be erased through a compressor reset);
- Type G: manual restarting is possible but a switching off (< 1 minute) is necessary. If system is not reset, restarting is
impossible;
- Type H: some anomalies prevent from restarting, system should be reset by switching off > 1minute or through the
STOP;
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Page 33
- Type I: some anomalies reset restarting and cancel this function;
- Type L: some anomalies reset restarting and cancel this function blocking the system (if anomaly persists, just a reset
can unblock the system);
Note: automatic restarting is possible only if system is in running condition (refueling or regeneration started from a
refueling process). In any other case (such as regeneration automatically started from a stand-by after a filling), only
manual restarting is possible.
The table also shows Fault/Hazard conditions.
System Response Time, type of restarting and Fault/Hazard conditions
Device/
Fault/Hazard condition
Error
Number
Test Interval
function
type
Hazard
1
LPT
Inlet Pressure < 3.5” water column
B
~ 10ms
(Low Pressure
(test disabled during the
Transducer –
first seconds of appliance
low limit)
supply)
2
LPT
Inlet Pressure > 20“water column
B
~ 10ms
(Low Pressure
(tested only after 5
Transducer –
minutes running)
high limit)
3
HPT
Outlet Pressure > 2% of max allowed
B
~ 10ms
(High Pressure pressure
(test disabled during the
Transducer –
first seconds of appliance
high limit)
supply)
4
HPT
Sensor signal under voltage < 0.4V
B
~ 10ms
(High Pressure
(test disabled during the
Transducer –
first seconds of appliance
low limit)
supply)
5
AIR FLOW
Air Flow position incoherent with fan
B
~ 10ms
(inadequate
condition. Fan on and Air Flow down.
(test disabled during the
air flow)
first seconds of appliance
supply)
6
AIR FLOW
Air Flow position incoherent with fan
B
~ 10ms
(flow meter
condition. Fan off and Air Flow up.
(test disabled during the
out of order)
first seconds of appliance
supply)
7
COMBI
With Combi Valve on, current <=300mA A
~ 10ms
VALVE
or > 2A.
(test disabled for 2s when
With Combi Valve off, current > 300mA.
element is ON or OFF)
8
INTERNAL
Gas concentration > 20% LEL
E
~ 10ms
GAS ALARM
(test disabled during the
first minute of system
starting)
9
INTERNAL
Gas sensor reference voltage < 1V o >
E
~ 10ms
GAS ALARM
3,2V
(test disabled during the
first minute of system
starting)
10
INTERNAL
Gas sensor heat current < 25mA o >
E
~ 10ms
GAS ALARM
90mA
(test disabled during the
first minute of system
starting)
11
EXTERNAL
Gas concentration
E
~ 10ms
GAS
> 20% LEL
(test disabled during the
SENSOR
first minute of system
(OPTIONAL)
starting)
Table 10 – System response time
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Response
time
~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
Page 34
System Response Time, type of restarting and Fault/Hazard conditions
Condenser (Peltier), Vaporizer or
A
Condenser (Peltier),
Column Heater are not working
Vaporizer or Column
correctly or current into the condenser
Heater are verified in
< 3A
regeneration in times
Tmis_pelt, Tmis_naf,
Tmis_col (mapped
parameters). Condenser
current verified every
10ms when is on (test
disabled in the first
seconds of starting and for
2s when element is ON)
13
BY PASS
With ByPass Valve on, current <=200mA A
~ 10ms
VALVE
or > 2A.
(test disabled for 2s when
With ByPass Valve off, current > 200mA.
element is ON or OFF)
14
DRYER
Condenser temperature < -55°C or >
B
~ 10ms
CONDENSER
105°C
(test disabled in the first
TEMPERATURE
seconds of appliance
starting)
15
DRYER
Vaporizer temperature < -55°C or >
B
~ 10ms
EVAPORATOR 105°C
(test disabled in the first
TEMPERATURE
seconds of appliance
starting)
16
DRYER
Condenser current >10A
A
~ 10ms
PELTIER
Condenser current verified
CURRENT
every 10ms
Condenser over current
verified every ~ 10ms
(test disabled in the first
seconds of appliance
starting and for 2s when
element is ON)
17
MOTOR
Triac short circuit
G
~ 10ms
TRIAC
when engine is off (test
disabled when element is
OFF)
18
MOTOR
TCO open for excessive engine
C
~ 10ms
TCO
temperature
when engine is on (test
disabled for 1s when
element is ON)
19
MOTOR
Engine current < 1A or >10A.
A
~ 10ms
when engine is on (test
disabled for 12s, if Tamb<10°C, or 7s, if Tamb≥-10°C,
when element is ON)
20
SUDDEN
Unexpected outlet pressure drop
D
~ 1s during refuelling
PRESSURE
DROP TEST
Table 10 – System Response Time (Continued)
12
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DRYER
GENERAL
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~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
Page 35
System Response Time, type of restarting and Fault/Hazard conditions
Excessive BlowDown pressure
A
When a refueling or a
regeneration starts
22
BLOWBACK
Back-pressure (BlowBack)
E
5s after the refueling stop
and during the first
seconds of supply (after
about 6 sec) BlowBack
activates (if test KO,
system repeats after 16 sec
then every 15 min; you can
force test by pressing
STOP)
23
SUDDEN
Unexpected outlet pressure increase
D
~ 1s during refueling
PRESSURE
RISE
24
HOSE TEST
High pressure gas leakage
D
After 6 seconds refueling
(repeated after 36 seconds
if first test fails, repeated
after empty tank if
enabled), every 130 min
refueling and when outlet
pressure is 97% of the final
one allowed and system is
refueling from at least 5
min.
Hardware fault
25
AMBIENT
Amb temp -45°C or > 55°C
B
~ 10ms
TEMPERATURE Difference of temperature between the
(test disabled in the first
SENSORS
two sensors > 8°C
seconds of appliance
starting)
26
START
Start button pressed for > 30s
B
~ 10ms
BUTTON
when start signal is present
(except if during the first
minute of system starting
is in Map/Cal error)
27
STOP
Stop button pressed for > 30s
I
~ 10ms
BUTTON
when stop signal is present
(except if during the first
minute of system starting
is in Map/Cal error)
Pressure management faults
28
PRESSURE
Inadequate outlet pressure increase
D
~ 10 minute refueling
RISE TEST
Table 10 – System Response Time (Continued)
21
39.0151
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~2s
~2s
~2s
~2s
~2s
~2s
~2s
~2s
Page 36
29
30
31
System Response Time, type of restarting and Fault/Hazard conditions
Counter timer faults
MAX
Max number of error for restarting
H
After a
RESTART
reached
refueling/regeneration
stop due to error.
At any appliance starting
(supply).
MAXFILL
Max refueling time allowed for refueling D
~ 1 s refueling
TIME
reached
POWER OFF
Max number of appliance reset during a H
At any appliance starting
refueling/regeneration cycle for
(supply).
restarting reached
~2s
~2s
~2s
Software faults
32
33
34
EEPROM
FLASH
RAM
EEPROM writing error
FLASH corruption (CRC error)
RAM corruption
F
F
F
35
MAP
EEPROM KO
REMOTE
COMMUNIC.
STATUS
RS-232
EEPROM mapping/calibration
parameters error
Communication failure
L
36
37
38
WATCH
DOG
Corruption of packages sent to RS232
(CRC error)
~2s
~2s
~2s
B
At any EEPROM writing
~ 40 s
~1s
(test disabled in the first
10s of system supply)
At any appliance starting
(supply).
~ 10ms
NA
At any packaged received
NA
A
~ 260ms
~2s
~2s
~2s
SW execution interrupted (e.g. in case
of endless loop) for >260ms
Table 11 – System Response Time (Continued)
Notes: test effects (if enabled) are active only if system is in a precise condition (in addition to table indications) when
the appliance is required to put itself in safe condition:
• Refueling /Regeneration: 1,3,4,5,6,7,13,14,15,18,19,21,25,32,33,34,36
• Running (refueling or regeneration started from refueling): 2
• Regeneration: 12, 16
• Refueling: 20, 23, 24, 28, 30
• All conditions: 8, 9, 10, 11, 17, 26, 27, 38
• Refueling and during the first seconds of supply: 22
• Refueling /Regeneration and at system starting (supply): 29
• At system starting (supply): 31, 35
• No effect: 37
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Page 37
11. RELIABILITY TECHNICAL DATA
Funzioni di Safety
functions
The tables show appliance reliability data:
• λS failure probability for Safety failures;
• λD (DD) failure probability for diagnosed Dangerous failures;
• λD (DU) failure probability for not diagnosed Dangerous failures;
• λNE failure probability for failures not involving safety functions and with no effect;
• Diagnostic Coverage (DC);
• Safe Failure Fraction (SFF).
λS [1/h]
λD (DD) [1/h]
λD (DU) [1/h]
λNE [1/h]
SF1
6,793E-06
7,882E-07
2,896E-07
2,927E-07
SF2
6,857E-06
3,662E-06
6,512E-07
3,737E-07
SF3
3,034E-06
2,721E-06
8,574E-07
2,020E-07
SF4
2,166E-08
5,674E-07
2,307E-07
1,920E-07
SF5
3,180E-09
5,261E-07
2,244E-07
1,895E-07
SF6
6,636E-06
1,122E-06
6,836E-07
2,017E-07
Table 11 – Failure Probability
Diagnostic Coverage
λD (DD) / λD [%]
SF1
73,13
SF2
84,90
SF3
76,04
SF4
71,10
SF5
70,10
SF6
62,15
Tabella 12 - Diagnostic Coverage
Safe Failure Fraction
(λS+λD (DD))/(λS + λD) [%]
SF1
96,32
SF2
94,17
SF3
87,03
SF4
71,86
SF5
70,23
SF6
91,90
Table 13 - Safe Failure Fraction
•
•
•
HFT = 0 (Hardware Fault Tolerance)
SC = 1 (Systematic Capability)
Tipo = B
Reliability data are assured for a life expectancy of 10 years.
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Page 38
12. DISPOSAL
RIGHT DISPOSAL
At the end of the HRA’s life, it should be removed and disposed according to installation Country authorities having
jurisdiction.
A suitable separate collection for the following recycle and environmental disposal helps to avoid possible negative
effects on environment and health and favours re-use and/or recycle of HRA materials.
DO NOT DISPOSE COMPRESSOR TOGETHER WITH DOMESTIC WASTE
PHILL CONTAINS MATERIAL ABSORBING MERCAPTAN FROM NATURAL GAS DURING REFUELING
OPERATIONS
----------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------Waste from Electrical and Electronic Equipment (WEEE)
(Valid for European Union and other European Countries with waste
separate collection systems)
This symbol
on HRA, or on its documents means that product
should be disposed at the end of its life according to directive
2002/96/CE about waste from Electrical and Electronic Equipment
(WEEE) and implementation in national law.
HRA should not be disposed as urban waste but rather be delivered to
the suitable collection point for electrical and electronic equipment.
Phill contains material absorbing mercaptan from natural gas durint
refueling operations.
In case of wrong HRA disposal, you will be responsible for it in accordance with laws in force.
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13. WARRANTY CERTIFICATE
WARRANTY CONDITIONS
M.T.M. Srl guarantees products for 24 months starting from the date of purchasing, within the limit of 2,000
working hours.
Purchasing should be proved by a fiscally valid receipt issued by the seller (fiscal ticket, invoice or transportation
bill) identifying the product, the date of purchasing and/or delivery.
During the whole warranty period M.T.M. Srl engages itself to:
(a) restore faulty products assuming all burdens of expenses concerning spare parts and transportation
(b) replace faulty products not usefully repairable (e.g. when repair will cost more than replacement).
GENERAL CONDITIONS
In order to benefit from warranty, the user will contact the seller and/or installer that will repair the machine
having ascertained the working defect.
If seller and/or installer cannot solve the problem, the machine will be forwarded to BRC FuelMaker that will repair
it or replace it with a new one at its own discretion.
The machine will be returned to BRC FuelMaker in its original packaging; lack of this packaging will automatically
cause the warranty forfeiture.
Warranty will be acknowledged only if the purchasing receipt will be sent by fax or mail at the moment of the
intervention request:
BRC FuelMaker – Warranty Dept.
Fax: +39 0172.486.630
E.mail: [email protected]
This warranty will not cover:
a) Fair wear and tear
b) Damages deliberately caused or due to negligence
c) Damages caused by inobservance of working instruction or by a wrong installation
d) Damages on non-functioning components that do not jeopardize the regular machine work, scratches and
difference in colours included
e) Accidental damages caused by foreign body or substance, especially included the non-standard composition
of the gas supplied to the machine (gas quality).
f) Repairs carried out by unauthorized assistance centres or repairs realized with non original spare parts
g) Damages caused by transportation
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14. CE CONFORMITY DECLARATION
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15. CERTIFICATE SIL 1
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